Ultrastang performance / Rosehill Performance Parts Lincoln Mk VII
Rear Disc Conversion Bracket Kit Installation Instructions
For a general visual instruction on the assembly of the
Lincoln Mk VII rear disc brake installation procedures, go to:
http://www.ultrastang.com/Page.asp?PageID=16
WARNING: Some parts may have sharp edges. Please Handle carefully!!!
REAR DRUM DISASSEMBLY:
1. Jack up the rear of the vehicle and support it with jack
stands. Remove the rear wheels, and then remove the brake drums.
2. Remove the parking/emergency brake cable end from the brake shoe lever, and
then remove the cable from the drum brake backing plate. TIP: Slip a small
diameter hose clamp around the parking brake cable’s barbs & tighten just enough
to compress all the barbs evenly so they can be pulled through the backing plate
hole. Once the barbs are sticking out the backside of the hole, release the hose
clamp completely and pull the cable out through the backing plate hole.
3. Remove the (4) 3/8” drum backing plate/axle bearing retainer nuts with a
9/16” socket –accessed through the hole on the face of the axle flange.
4. Slide the axle out of the housing.
5. Disconnect the 3/24” hard brake line fitting from the drum brake wheel
cylinder and remove the drum brake backing plate assembly.
6. Remove any old gasket material from the rear end housing’s end flange surface
or from the surface of the axle-bearing retainer that may be present.
7. Ensure there is no excessive welds or slag in the area where the axle flange
is welded to the axle tube.
NOTE: This is a good time to replace axle seals & to check for worn axle
bearings. To check axle bearings: Place your thumb on the outer portion of the
bearing and give it a swift spinning action, If the bearing “free-wheels” for
more than 1½ revolutions, REPLACE THE BEARING!! Sealed bearings are lubricated
for the life of the bearing at the time of manufacture. A good bearing should
have a fair amount of “drag” or “resistance” to spinning freely. Freewheeling
indicates most of the internal lubrication has been lost.
Mk VII REAR DISC BRAKE ASSEMBLY:
1. Slide the new axle retainer gasket (Fel-Pro p/n 55001 –purchased from the
parts store) & the axle housing end spacer over the axle shaft (in that order).
2. Slide the axle assembly back into the rear end housing while holding the
weight of the axle up off of the seals as the axle is being slid into place.
TIP: Dragging the full weight of the axle across the seals leads to seal damage
and premature seal failure (leaks).
Housing End Flange Bolt Hole Locations: Looking at the (4) bearing retainer
holes on the driver’s side of the rear end housing flange: (NOTE: Some housing
end flanges have a 5th-hole at the bottom, center portion of the housing’s end
flange. This is a weep hole, so disregard it as a hole-position). Hole position
#1 is located in the upper left-hand corner & proceeding in a clock-wise manner,
ending at position #4 in the lower left-hand corner of the flange.
1-O 2-O
3-O 4-O
3. Slide a 3/8” flat washer onto one of the 3/8”-24 x 1-1/4” bolts and insert
the bolt into position #1 on the axle housing end flange, with the bolt threads
facing inward toward the center of the housing. Take another one of the 3/8”
flat-washers and grind a flat spot on one side to “clearance it,” to clear the
axle flange, then slide the washer over the threaded end of the 1-1/4” 3/8” bolt
(at position #1), then install a 3/8” lock nut –DO NOT TIGHTEN YET. (NOTE: The
original T-Bolt can be used in the same format as Ford did and forego the
modification of the washer. Owners prerogative.)
4. Rotate the axle flange’s access hole (clock-wise) to position #2 (upper
right-hand corner, looking at driver’s side). Install a 3/8” flat washer on one
of the 3/8”-24 x 2-1/2” bolts then install the bolt through the access hole in
the axle flange and through the bearing retainer/axle housing end flange.
5. Rotate the axle flange’s access hole (clock-wise) to position #3 (lower
right-hand corner). Slide a 3/8” flat washer onto one of the 3/8”-24 x 2” bolts
& insert the bolt into position #3 through the axle flange’s access hole and
into the axle bearing retainer/housing end flange.
Mk VII REAR DISC BRAKE ASSEMBLY: (cont)
6. Rotate the axle flange’s access hole (clock-wise) to line up with the hole at
position #4 (lower left-hand corner). Slide a 3/8” flat washer onto one of the
3/8”-24 x 2½” long bolts & insert it into position #4 through the axle flange’s
access hole of the axle and through the bearing retainer/axle housing end
flange.
7. Take the (3) black tubular spacers & place one each over the threaded ends of
the 3/8” bolts at positions: #2, #3, & #4. Ensure there is no welding slag on
the axle tube that would prevent the main bracket from making full contact with
all three tubular spacer.
8. Slide the anchor plate adapter bracket into position over the threaded ends
of the 3/8” bolts at positions: #2, #3, & #4.
Mk VII Splash Shield Modifications:
1. Drill a 25/64” hole in the center of the inner curve of the splash shield
where the splash shield fits around the axle tube.
2. Place 3-4 3/8”flat washers on the 2-1/2” bolt in Position # 3. This will
align the splash shield with the offset level on the rear tabs.
3. Slide this hole (and the splash shield) onto the threaded end of the bolt at
position #4.
4. Place a 3/8” flat washer & a 3/8” nut on the threaded end of the bolt at
position #4, and tighten the nut just enough to hold tension on the splash
shield to keep it from easily moving around, but where the inner curve of the
shield can be positioned evenly around the axle tube without the shield actually
touching the axle tube.
5. Once the shield is evenly positioned, clamp the trailing ends of the shield
to the anchor plate adapter bracket (don’t clamp the shield too tight, the thin
metal will bend easily).
6. Using the two ½” holes in the adapter bracket as a drill guide, take a ½”
drill bit & drill the two holes through the shield –taking care to drill slowly
to avoid ripping the holes in the thin metal of the shield as the drill bit
passes all the way through. NOTE: The ½” holes may be slightly undersized due to
paint & machining techniques. Enlarge holes if necessary.
7. With the shield still clamped into place, note the placement of the bolt in
position #3 (on the backside of the shield). Mark the shield for a bolt/nut
“clearance notch” to be cut out.
8. Unclamp the shield & remove the nut from position #4 so the shield can be
removed.
9. Make a clearance notch, remove any burrs from around the drilled holes or
notch, then prime and paint the shield.
10. Re-install the finished shield onto the 3/8” bolt at position #4. Install
flat washer and nut, but DO NOT TIGHTEN YET.
Installing The Caliper Anchor Plate:
1. Slide a 12mm lock-washer & one large flat-washer onto one of the M12 x 1.75 x
35mm long metric bolts.
2. Pass the M12 x 35mm long bolt through from the backside of the splash shield
& then through the lower hole in the anchor plate adapter with the threaded end
pointing outward.
3. Mount the lower end of the caliper’s anchor plate on this M12 x 35mm long
bolt ,Just start the threads of the bolt into the anchor plate, but DO NOT
TIGHTEN YET.
4. Slide (4) 3/8” flat-washers over the threaded end of the 3/8” bolt at
position #2.
5. Take the left-hand parking/emergency brake cable anchor bracket and slide the
small diameter bolt hole (on the cable bracket) over the threaded end of the
3/8” bolt at position #2 & install a 3/8” flat-washer & lock-nut – but DO NOT
TIGHTEN YET.
6. Slide a 12mm lock-washer & one flat-washer onto one of the M12 x 1.75 x 50mm
bolts
7. Pass this M12 x 1.75 x 50mm long bolt through the ½” hole in the
parking/emergency brake cable anchor bracket.
8. Slide (3) large flat washers (shims) over the threaded end of the M12 x 1.75
x 50mm bolt & then pass the bolt through the splash shield/caliper anchor plate
adapter bracket.
9. Swing the upper end of the caliper anchor plate into position and lined up
with the anchor plate adapter’s upper hole, and thread the M12 x 1.75 x 50mm
long bolt into the upper end of the caliper anchor plate.
10. Snug all bolts/nuts up evenly and then tighten to specs.
NOTE: Installation of the right-hand side brake adapter brackets installs just
the same as on the left-hand side, only the bolt hole locations will be indexed
in a (counter-clock-wise manner) instead of a clock-wise manner).
Torque Specifications:
1. 3/8-24 prevailing torque lock nuts: 29 ft/lbs. (approx. 40 N/m).
2. M12 x 1.75 metric bolts: 110 ft/lbs. (approx. 150 N/m).
3. WARNING: Prevailing torque lock nuts can be torqued a maximum (5) times
before they
must be discarded & replaced.
You Can Now Install the Mk VII Brake Components:
1. Starting with the anti-rattle spring on the lower portion of the anchor
plate.
2. Then install the inner brake pad.
3. Then the rotor. (Use an old lug nut to hold the rotor in position on the axle
flange).
4. Then install the outer brake pad.
5. Do not install the caliper before installing the flexible hose on the caliper
first.
Caliper Flexible Brake Hose Modification:
1. Chuck the brass end of the flexible brake line (on the end with the stamped
steel bracket) in a vise.
2. Protect the brass from the jaws of the vise.
3. Remove the stamped steel bracket from the rectangular pad (on the hose end)
by carefully chiseling away the outer edges of the rectangular brass pad.
4. Remove & discard the stamped steel bracket.
5. Install the flexible brake hose on the caliper (with the two copper washers),
BEFORE mounting the caliper onto the anchor plate.
6. Now with the hose installed, the caliper can be installed on the anchor
plate.
Parking/Emergency Brake Cable:
1. Install the parking brake cable through the hole of the brake cable’s anchor
bracket.
2. Pull the cable through the hole until the barbs lock into place.
3. Route the flexible brake line hose 90° underneath the parking brake cable’s
barbs.
4. Take a wire-tie (tie-wrap, zip-tie, whatever you may know it by), and secure
the brake hose to the parking brake cable’s barb with the tie.
Rear 3/16” Hard Brake Line Modification:
You can shorten the existing 3/16” hard brake lines, to attach to the rear disc
brake’s flexible lines, or you can run a completely new hard line to both rear
caliper brake hoses.
WARNING: NEVER use tubing compression fittings on a vehicle’s braking system
when making up new lines or modifying existing brake lines!! ONLY use inverted
flare fittings with double-flared hard line ends! Compression fittings can blow
apart under the extreme pressures that can be experienced in braking systems.
Parking Brake Cable End Linkages:
1. Take the stock stamped steel Mk VII’s parking brake cable
end-to-caliper-lever linkage and cut a 1/8th-inch wide slot through one edge of
the linkage and down to the hole in the center (where the cable normally comes
through the center hole).
2. Slip the slotted portion of the linkage over the end of your existing parking
brake cable end.
3. Attach the linkage to the caliper lever with the MkVII’s stock pin & retainer
clip.
Parking Brake Cable End Linkages: (cont)
4. Check to make sure the parking brake cable(s) will not come in contact with
the backside of the tire(s). You may have to restrain the cable(s) from making
contact with the backside of the tire(s).
Rear Disk Insert Ring:
If applicable, two aluminum rings are included in your kit. These rings center
the rear disk on the axle. Ensure that the axle register is clean and free from
debris. Ensure that the register has not been damaged from previous maintenance
that included a hammer to install an axle, causing the register flange to
“mushroom”. If damaged, file / grind register down until the Register Ring will
fit all the way onto the axle without restrictions. Clean inner / outer disk
flange to ensure proper fit of the register ring.
Follow ALL safety guidelines and procedures as you would with any braking
system.
For a general visual instruction on the assembly of the Lincoln Mk VII rear disc
brake installation procedures, go to: www.ultrastang.com
LIABILITY DISCLAIMER:
The seller, Ultrastang Performance or Rosehill Performance Parts, hereby
expressly disclaims all warranties, either expressed or implied, including any
implied warranty or merchantability of fitness for a particular purpose.
Ultrastang Performance or Rosehill Performance Parts neither assumes or
authorizes any other person to assume for it any liability in connection with
the sale of this merchandise. Purchaser/User of this product uses such product
entirely at ones own risk.
Thank you for your purchase of this Lincoln Mk VII rear disc brake conversion
adapter bracket kit!!